Advancing Automation: Iiot and Industry 4.0

Advancing
Automation
IIoT and Industry 4.0
July 2019
Volume XVIII
INTRODUCTION
Smart manufacturing is about quickly and easily adapting manufacturing capabilities to where
they’re needed based market demands. Industry 4.0 and the Industrial Internet of Things (IIoT)
are ways forward toward that goal, enabling new industrial landscapes. But the unique demands
of industrial automation are not easily solved with commercial IoT solutions. The “industrial” in
Industrial IoT encompasses tools that simplify instrument maintenance, extended-life batteries
that enable remote wireless devices, edge programmable industrial controllers and more. Explore
a range of tools and techniques from some of industry’s IoT leaders in this sponsored ebook from
Automation.com.
TABLE OF CONTENTS
Advanced Tools Simplify Instrument Maintenance Page 5
by: Endress+Hauser
Extending Battery Life in Remote Wireless Applications Page 11

by: Tadiran Batteries
Meet the Future: Edge Programmable Industrial Controllers

by: Opto 22 Page 18
Smart Manufacturing: Keep Your Competitive Edge

by: MAVERICK Technologies Page 28
Bridging the Gap Between HART Devices and IIoT, the Industrial Page 34
Internet of Things
by: Moore Industries
Make Way for the IIoT: Solving Automation’s Unique Challenges Page 39
by: Hilscher
The IIoT – Enabler for New Industrial Landscapes Page 45

by: Voith
Next-gen Wireless: Industry 4.0 Essential Page 50

by: Nokia
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Advanced Tools Simplify Instrument Maintenance
Hardware and software developments make preventive maintenance easier, lower costs,
reduce parts inventories, and prevent unexpected equipment failures.
By: Jon Dietz, Endress+Hauser
In many process plants, maintenance of instrumentation (Figure 1) falls into one of two categories. The first is “too little,
too late,” where instrumentation fails due to a lack of preventive maintenance, often shutting down processes. The
second category is “too much maintenance,” where companies remove, calibrate, clean and service instrumentation that
doesn’t need it, at a high cost for parts, labor and equipment downtime.
Some instrument vendors now offer capabilities and services to help end users manage maintenance through on-line
diagnostics, asset management, proper scheduling of maintenance tasks, and automatic alerts when problems come up.
This article describes how end users can exploit these technologies to simplify maintenance, lower costs, reduce parts
inventories, and prevent unexpected equipment failures.
Instrumentation that Diagnoses Itself
Smart flowmeters and other process instruments have been available for years in “smart” versions, providing vital
information for maintenance. For example, 4-20mA HART devices have been available since the 1980s. HART
superimposes 35-40 digital parameters onto the 4-20mA signal, which can include device status, diagnostic alerts,
configuration parameters, and so on. Fieldbus instruments provide much of the same information through various
protocols such as EtherNet/IP and Profibus PA.
Unfortunately, over 60% of instruments are used only to measure the primary process variable, with the status and
diagnostic data ignored by the control system. Maintenance technicians often have to access the data with handheld
devices that plug into the flowmeter. A lack of understanding, training and useful software to process the data might
account for maintenance departments not taking advantage of this capability.
Advancing Automation eBook Vol. XVIII PAGE 5

Instrument suppliers recognized the problem and have gone to great lengths to equip flowmeters and other devices
with on-board diagnostics, status information and other secondary device parameters that are needed by maintenance
people—and they’ve provided the software needed to make all this data easily accessible and usable.
For example, flowmeters from Endress+Hauser are typically equipped with Heartbeat Technology, which provides
a wealth of status and diagnostic information, and performs vital functions such as condition monitoring and insitu-
verification.
Condition monitoring recognizes if the measurement performance or the integrity of the flowmeter are impaired. The
monitoring values are transmitted to an external condition monitoring system, such as Endress+Hauser’s PC-based
FieldCare software. FieldCare can be used to recognize trends in the secondary measured values, and to evaluate
relationships among individual parameters.
Legal requirements may call for flowmeters or other instruments to be verified calibrated periodically. This is normally
done by removing the flowmeter from the process, taking it to a flow lab or calibration rig, and quantitatively comparing it
to a traceable standard.
With modern instruments, the flowmeter’s transmitter electronics continuously run a qualitative assessment so all
relevant components which influence the device function and integrity are checked. This confirms and can document
by verification that none of the meter components have drifted outside original calibration tolerances. If the flowmeter
calibration frequency can be extended, this represents a tremendous savings in labor and process down time.
More details can be found in the Flow Control article, “How Flowmeters Perform Self-Verification” (https://www.
flowcontrolnetwork.com/how-flowmeters-perform-self-verification/).
Maintenance Management
Modern instrumentation provides status and diagnostic information, but processing all of this data is often a
problem. For example, a chemical plant in Gendorf, Germany, has more than 4,000 instruments measuring level, flow,
temperature, pressure and other parameters. Having its control systems read all the diagnostic information from all 4,000
devices, analyze it for problems, and issue instructions to the maintenance department would be a daunting problem
for the plant’s control system programmers. It would also burden the control system with data not relevant to its primary
task, which is real-time process control.
Instead, instrument manufacturers have developed software packages that perform all those functions. The packages fall
into two basic categories: Instrument management programs, which analyze real-time information from instrumentation;
and asset management software, which keeps track of every instrument in the plant and stores vital data, such as
manuals and parts lists.
Instrument management programs perform several functions to aid maintenance departments, including:
• Configuration—helps maintenance configure new instrumentation during initial installation or when replacing an
existing instrument.
• Condition monitoring—as noted above, used to analyze real-time data coming from instrumentation, look for
problems, and notify the maintenance department when a device needs attention prior to failure.
• Life cycle management—tracks the entire life cycle of an instrument, from initial configuration to calibrations and
repairs, and provides information for audits and safety regulations.
Advancing Automation eBook Vol. XVIIII PAGE 6

While a particular instrument manufacturer can
provide information for its own instruments, what
about all the other instruments in a plant from
different manufacturers? Fortunately, standardization
across the instrumentation industry makes that
information available.
Device Description (DD), enhanced device

description language (EDDL), Device Type Manager
(DTM), and HART and fieldbus configuration files are
available from all manufacturers, can be accessed
easily from various web sites, and then loaded into
the instrument management program.
Thus, a program like Endress+Hauser’s FieldCare Figure 2: Asset management programs provide equipment manuals,
software not only has information about its own parts lists and other information to handheld devices, such as
instruments, it can support over a thousand process Endress+Hauser’s FieldXpert.
instruments and analyzers from other manufacturers.
Asset Management
When a plant has thousands of instruments, keeping track of manuals, parts lists, audit reports, maintenance schedules
and other information can be a nightmare. A maintenance asset management program gathers all this information,
digitizes it, and makes it available to maintenance technicians via handheld devices (Figure 2).
An asset management program typically provides:
• Instrument Manuals—Modern manuals are available in digital form and are easily downloaded into the data base;
older paper manuals can be scanned
• Parts lists—Like manuals, parts lists can be downloaded or scanned
• Compliance—The software
tracks all instrument activities,
including calibrations,
verifications and maintenance
performed to meet various
industry and government
regulations
• Documentation and reports—
The software can produce
audits and regulatory reports
that meet government and
industry standards
• Maintenance management—
Determines when instruments
need to be serviced, calibrated
or verified, and notifies
maintenance Figure 3: Instrument data from asset management software such as Endress+Hauser’s
W@M program can be accessed from workstations or handheld devices.
• Communications—The software
can share data with other
maintenance management programs, historians, spreadsheets, etc.

All this information can be kept on site or in the Cloud, where it can be accessed from a workstation (Figure 3) or a
portable handheld device.
Getting Started
Many plants do not have sufficient information regarding their installed base of process instruments and analyzers, and
over time the plants are modified and instruments change, worsening the situation.
One of the best ways to address this issue is by implementing a maintenance management program, often with the aid
of a major instrument vendor. Most such vendors can come to a process plant, do an assessment of the instrumentation
installed base, and make management recommendations on what needs to be done to improve the current situation.
For example, Endress+Hauser can perform an Installed Base Analysis, which consists of:
• Instrument inventory—Find and list all on-site devices to enable further transparency, regardless of manufacturer
• Assess device criticality and maintainability—Define and classify critical measuring points and its maintainability to
ensure maintenance tasks can be performed easily and effectively
• Recommend adequate maintenance strategy—Evaluate current maintenance activities and recommend
improvements to achieve a balanced maintenance program
• Identify obsolete equipment—Includes a migration plan to modernize the plant
• Reduce complexity—Includes recommendations to standardize instrumentation and minimize spare parts.
At the completion of the assessment, the instrument vendor will address its recommendations by providing key
information to facilitate relevant decision making regarding the maintenance and quality improvements, obsolescence
and spares management of respective installed base assets. If the plant agrees, the project begins by implementing the
new maintenance program within the scope of a service agreement. The data describing each instrument is entered into
the database and maintained over time to enable the user to continuously access to an up to date information at any
time and from any location.
As noted above, the software may already have most of the data needed, such as DD and DTM files, manuals, etc.
In some cases, old manuals and parts lists may have to be found and scanned in. Eventually, the data base will be
populated
A wastewater treatment plant in Thun, Switzerland (Figure 4) had Endress+Hauser conduct an IBA, and then installed
W@M Life Cycle Management software.
Once the data had been recorded, a connection was established to the control system. The visualization program
allows the plant to quickly identify a measuring device needing attention. The necessary information can then be quickly
accessed, including the right operating manuals, ordering information, maintenance reports, software drivers and spare
parts.
The chemical plant mentioned above also conducted an IBA and adopted such a program to maintain its 4,000
instruments. In the old days, documents such as calibration reports had to be scanned and filed manually. Today, this
information is available whenever and wherever it is needed. The plant is now able to identify every one of its devices
and react quickly in the event of a malfunction.

Figure 4: After an audit, this wastewater treatment plant in Switzerland installed Endress+Hauser’s W@M Life Cycle Management
software.
Summary
Modern instrumentation and related maintenance strategies are making it much easier for process plants to perform
preventive maintenance, eliminate process shutdowns from failed instruments, and save time and money by avoiding
unnecessary maintenance activities.
Initial implementation of an instrumentation management system can be a daunting task, but instrument vendors can
provide assistance as required.
About the author:
Jon Dietz is the national field service manager for Endress+Hauser

and has national responsibility for all after-sale customer field
support. He is a U.S. Navy veteran (Advanced Electronics
Program) and prior to joining Endress+Hauser supported Doppler
radar applications within the agricultural industry. Dietz has
been with Endress+Hauser for 26 years. He began his career
with Endress+Hauser as a field service engineer and has been
in his current position since 1999. Visit us.endress.com for more
information.

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Extending Battery Life in Remote Wireless Applications
By: Sol Jacobs, Tadiran Batteries
A growing number of industrial automation and Industrial Internet of Things (IIoT) applications require industrial-grade
lithium batteries to deliver long-term power, especially in challenging environments.
Battery-powered solutions can be installed far more cost effectively than hard-wired solutions tied to the AC power
grid, which costs roughly $100/ft for any type of hard-wired device, even a basic electrical switch. This expense rises
exponentially in extreme environments and hard-to-access locations.
If the remote wireless device draws small amounts of daily average current (microamps) it can typically achieve long
operating life using an industrial-grade primary (non-rechargeable) lithium battery. If the device draws higher amounts of
average daily current (milliamps), it could quickly deplete a primary battery, necessitating the use of an energy harvesting
device in combination with a lithium-ion (Li-ion) rechargeable battery to store the harvested energy.
Lithium thionyl chloride (LiSOCl2) batteries last the longest

Lithium batteries are preferred for long-term deployments because of their high intrinsic negative potential, which
exceeds that of all other metals. As the lightest non-gaseous metal, lithium offers the highest specific energy (energy per
unit weight) and energy density (energy per unit volume) of all available battery chemistries. Lithium cells operate within
a normal operating current voltage (OCV) range of 2.7 to 3.6 V. Lithium batteries also contain no water, allowing them to
endure extreme temperatures without freezing.
Numerous primary lithium chemistries are available including iron disulfate (LiFeS2), lithium manganese dioxide
(LiMNO2), lithium thionyl chloride (LiSOCl2), and lithium metal-oxide chemistry (see Table 1).

Table 1
Of all these choices, lithium thionyl chloride
(LiSOCl2) batteries deliver the longest battery
life in extreme environments, making them
preferred for AMR/AMI metering, M2M,
SCADA, tank-level monitoring, asset tracking,
environmental sensors, and other remote
applications.
Bobbin-type LiSOCl2 batteries feature the

highest capacity and highest energy density
of any lithium cell, along with an extremely
low annual self-discharge (under 1% per year
for certain cells), thus permitting up to 40-
year battery life. They also deliver the widest
possible temperature range (-80 to 125°C)
and feature a superior quality glass-to-metal
hermetic seal.
In addition, specially modified bobbin-type

LiSOCl2 batteries can be adapted for the cold chain, where wireless sensors continuously monitor the transport of
frozen foods, pharmaceuticals, tissue samples, and transplant organs at temperatures as low as -80°C. These batteries
can also handle extremely high temperatures. For example, specially modified bobbin-type LiSOCl2 cells are utilized in
active RFID tags that track the location and status of medical equipment without having to remove the battery prior to
autoclave sterilization, where temperatures can reach 125°C.
Lower self-discharge is crucial
Extended battery life reduces the total cost of ownership. Much attention is being drawn to boosting battery operating
life through the use of low-power chipsets and communication protocols. However, the potential energy savings from
these techniques fails to compare with the potential energy savings achieving by specifying a battery with a very low
annual self-discharge rate.
Self-discharge is a natural phenomenon that affects all batteries, as chemical reactions occur even when a battery is
in storage and not used. Self-discharge rates vary based on several factors, including: the current discharge potential
of the cell based on its design; the quality and purity of the raw materials; and the ability of the battery manufacturer to
manipulate battery passivation to retard the chemical reactions that cause self-discharge.
What is passivation?
Passivation is a thin film of lithium chloride (LiCl) that forms on the surface of the lithium anode, creating a high
resistance layer between the electrodes, thereby restricting the chemical reactions that cause self-discharge.
When a load is placed on the cell, the passivation layer causes higher resistance, which causes battery voltage to dip
temporarily until the discharge reaction slowly removes the passivation layer. This process continually repeats itself each
time the load is removed.
Different factors can influence battery passivation, including: the current capacity of the cell; length of storage; storage
temperature; discharge temperature; and prior discharge conditions, as partially discharging a cell and then removing the
load increases the amount of passivation relative to when the cell was new. Passivation is the tool that limits the self-
discharge of the battery. Unfortunately, it also restricts the potential energy flow rate of the cell.

Long-life batteries balance passivation and self-discharge: the “bottle analogy”
While passivation is necessary to reduce battery self-discharge, too much of it can restrict the energy from flowing when
you need it. Conversely, having very little passivation will enable a greater flow rate, but the trade-off is higher self-
discharge and shorter operating life. Comparing the impact of passivation on battery self-discharge and energy flow rate
is like comparing bottles of fluid:
• The volume of the glass/bottle is equivalent to battery capacity

• Evaporation/self-discharge is equivalent to capacity loss
• Flow volume is equal to discharge/energy flow
• Low liquid/electrolyte quality can lead to plugging the opening which will cause flow stoppage/passivation
• Low liquid/electrolyte quality can cause evaporation/self-discharge
• Lithium Thionyl Chloride batteries have “small openings”
• LMNO2 and alkaline batteries have “larger openings” so that they can provide higher flow rates but their larger
openings lead to more evaporation/self-discharge
• Large openings are good for fast flow/discharge but not for storing fluid for a long time
• For long operating life you need small opening for low evaporation/self-discharge
• Opening size / battery design is a critical issue - too large an opening and more evaporation/self-discharge, too small
an opening and there is no flow and the opening can be stuffed up (passivation)
• Fluid/chemistry quality is imperative to keeping impurities/passivation low
Bottle Examples Comparing flow rates
Comparing evaporation/self-discharge rates

Comparing evaporation/self-discharge rates
Passivation can create clogged openings that prevent flow
• Low quality fluid / electrolyte can freeze in the opening in cold

• Low quality fluid / electrolyte can plug up the opening in the heat
Combining low self-discharge and high pulses

The IIoT has increased demand for low power devices that require
periodic high pulses to support two-way wireless communications.
A standard bobbin-type LiSOCl2 battery cannot normally deliver

high pulses due to its low rate design. However, this can be easily
solved by incorporating a patented hybrid layer capacitor (HLC). The
standard bobbin-type LiSOCl2 cell delivers low daily background
current while the HLC handles periodic high pulses. The patented
HLC also features a special end-of-life voltage plateau that can be
interpreted to deliver low-battery status alerts.
Supercapacitors can also deliver high pulses electrostatically rather HLC

than chemically, making them popular for consumer electronics.
Supercapacitors are generally unsuited for industrial applications due
to inherent drawbacks such as short-duration power, linear discharge
qualities that prevent use of all the available energy, low capacity, low
energy density, and high annual self-discharge rates (up to 60% per
year).

Supercapacitors linked in series also require the use of cell-balancing circuits, which adds cost and bulkiness and
consumes extra energy, which reduces operating life.
High pulse requirements draw higher amounts of average daily current, so various techniques must be used to conserve
energy. These techniques include the use of low-power communications protocols (ZigBee, WirelessHART, LoRa, etc.),
low-power microprocessors, and by minimizing energy losses during data sampling and transmission.
How to choose an industrial-grade battery
When specifying an industrial-grade lithium battery, you must take into account various technical requirements,
including: the amount of current consumed in active mode (along with the size, duration, and frequency of pulses);
energy consumed in stand-by or sleep mode (the base current); storage time (as normal self-discharge during storage
diminishes capacity); expected temperatures (including during storage and in-field operation); equipment cut-off voltage
(as battery capacity is exhausted, or in extreme temperatures, voltage can drop to a point too low for the sensor to
operate); the annual self-discharge rate of the battery (which can approach the amount of current drawn from average
daily use).
High temperature applications can be especially problematic to certain chemistries. According to the Arrhenius Equation,
every +10°C rise in temperature causes the battery’s self-discharge rate to roughly double. Fortunately, specially
designed bobbin-type LiSOCl2 batteries can handle extreme temperatures without causing an accelerated self-discharge
rate.
Tests for self-discharge can be highly misleading
Choosing among batteries with the exact same chemistry can be challenging since a higher self-discharge rate may not
become apparent for years, and theoretical testing often underestimates the true effects of passivation and long-term
exposure to extreme temperatures. Here are some suggested methods to more accurately predict long-term battery
performance:
Actual results in the field: When an AMR/AMI meter manufacturer began replacing older generation systems after 28
years of operation, the batteries being replaced were still operating. Lab tests confirmed that these cells could have
operated for over 30 years.
Continuous long-term testing: Battery manufacturers need to continually monitor samples from every production lot
ever produced. For example, Tadiran has been continually testing production batches for over 40 years.
PulsesPlus™ batteries combine a bobbin-type LiSOCl2

cell with a patented hybrid layer capacitor (HLC) to
deliver the high pulses required for two-way wireless
communications.

Long term testing at 72°C: Arrhenius test
At 72°C, most batteries will self-discharge at a rate

roughly 32 times higher than at 22°C. By contrast,
superior quality bobbin-type LiSOCl2 battery can
withstand extended testing at elevated temperature
without experiencing such an accelerated self-
discharge rate.
Using a calorimeter: One of the most accurate

forms of testing for battery self-discharge is to use a
calorimeter to measure energy lost in the form of heat
energy.
If your application demands long-life power, then you

must conduct thorough due diligence when evaluating
potential battery suppliers. For example, access
to accurate long-term test data is essential when
specifying a long-life bobbin-type LiSOCl2 battery for meter transmitter units (MTUs) used in AMR/AMI utility metering
applications, where a large-scale battery failure can disrupt customer billing systems and disable remote service start-up
and shut-off capabilities. The possibility of such wide-scale chaos could force a utility to prematurely invest millions of
dollars to replace batteries early so as not to jeopardize data integrity.
Where extended battery life is essential, be careful to perform added due diligence, as battery manufacturer claims may
be highly misleading, failing to take into account the true impact of passivation and elevated temperatures on battery
operating life. When calculating your long-term cost of ownership, be sure to include all anticipated expenses related to
future battery replacements, along with the risks associated with premature battery failure.
About the author:
Sol Jacobs
VP and General Manager, Tadiran Batteries
Sol Jacobs has over 30 years of experience in powering remote

devices. His educational background includes a BS in Engineering
and an MBA.

Meet the Future: Edge Programmable
Industrial Controllers
A new kind of industrial controller simplifies and secures automation and IIoT projects,
while reducing cost and complexity
By: Benson Hougland, Opto 22
New projects
The manufacturer
Last year a glass products manufacturing company in Ohio presented their automation engineers with a new project:
data from manufacturing lines needed to appear in a web-based user interface (UI) the company’s supervisors already
used.
The UI showed production goals and sales from the company database. Supervisors needed to see real-time production
figures in order to compare them to goals and sales and adjust production accordingly.
How hard could it be? Almost everything was on premises.
• Field devices on the manufacturing lines were wired to local programmable logic controllers (PLCs), with field device
values in counts.
• Getting data from the PLCs required device-specific communication drivers. The engineers purchased and installed
them, chose the desired points, and mapped the points in a spreadsheet. Data in counts had to be converted to
engineering units.

• Next, the PLC data was networked to a PC-based HMI (human-machine interface) and a SCADA (supervisory control
and data acquisition) system. These systems required the engineers to configure data tags, drivers, and polling rate
assignments.
• Then, working with their information technology (IT) department, the engineers also configured the HMI and the
SCADA system to transport the data into the company database.
• Additional programming was required to make the data available to supervisors.
Though expensive and complicated, it worked. The engineers and the IT personnel could finally get back to other
projects they’d had to put on hold while figuring this one out. They wished there had been an easier, less costly solution.
And then the company realized that their supervisors needed more information from the manufacturing lines, as well as a
way to control some process elements. In addition, new production lines were being planned to manufacture a different
kind of glass. The new lines would require control and a similar complex architecture to share data with the supervisors’
interface.
The OEM
At about the same time, an original equipment manufacturer (OEM) in California was rethinking its machine design. The
OEM built ovens that were suited for a wide variety of industrial and commercial applications, and the company wanted
to differentiate its ovens from those of its competitors in order to increase sales.
Feedback from customers pointed to three ways they could improve:

• Make it easier for customers to integrate the oven with process control systems
• Add human-machine interface (HMI) options so customers could more easily monitor and control the oven’s
operation
• Reduce customer costs, especially for operation and maintenance
The OEM’s engineers explored a number of ways to achieve these customer requests.
They thought about ways to simplify

integration with popular process
control systems—for example,
drivers for an OPC UA server.
But because control systems are
proprietary, a driver would have to
be developed separately for each
system. Since the company’s ovens
were used with many types of
systems, a one-at-a-time approach
would not be cost effective.
Integration with existing HMIs would

run up against the same problem.
The engineers considered other
options for an HMI, including an
improved interface on the machine
itself and even a mobile app.
These ideas sounded possible but
expensive to develop.
Reducing customer costs seemed
even more difficult.

All their ideas depended on data. If they could get operational data from in-place ovens at customer locations, they
could analyze it to improve their products’ efficiency.
Data like that could also reduce customer costs by providing a new level of service. For example, the OEM could
track burner ignitors, anticipate failures, and call the customer in advance to avoid unplanned downtime. Scheduled
maintenance would likely be reduced as well, replaced by preventive maintenance and even predictive maintenance, to
determine the likelihood of failures before they occur.
Customers would appreciate these cost reductions and new services. But to get oven data from a customer’s site, the
OEM would have to gain access to the customer’s network. The customer’s IT department would have to open incoming
firewall ports and allow the OEM to request, or poll, the data. IT departments would never allow such a potential breach
to their network security.
How could the OEM redesign their ovens to meet their customers’ wishes and differentiate their products in the market,
without spending so much time and money and causing major security problems?
The challenge of the IIoT

CHALLENGE:
These two projects touch on three of the main challenges most automation engineers find today with the industrial
internet of things: complexity, security, and expense. Usually the extent of these challenges is not obvious before a
project begins; the challenges become more clear once the project is underway. Any IIoT or data-intensive automation
application seems to end up involving far more complexity, many more security risks, and much greater investment in
time and money than many companies want to expend or can afford.
Getting data from the edge of the network—from the sensors and actuators in factories, commercial buildings, and
remote sites—to the databases and people who need to use that data can be daunting. Bi-directional communication,
for control as well as monitoring and data acquisition, can be even tougher.
Most control systems and equipment use protocols and networks that are proprietary or specific to automation—
EtherNet/IP, Modbus, Profibus, serial, OPC. But computers
and mobile devices use standard Ethernet or
SOLUTION:
wireless networks and open protocols and
standards, like TCP/IP, HTTP/HTTPS, JSON, and
RESTful APIs.
Translating data between these systems and

moving it to where it’s needed involves a lot of
expense and middleware: computers, gateways,
drivers, parsers, custom software, licenses.

As soon as data moves outside its immediate network or off premises—for use in the company computer network, or
remote locations, or on a tablet or smartphone connected to the internet—middleware increases and security concerns
balloon. A typical setup includes many steps, as shown in the “Challenge” diagram above.
A new approach to automation and the IIoT

As controls engineers, we’re familiar with PLCs (programmable logic controllers) and PACs (programmable automation
controllers). Both have been used and improved over many years, incorporating capabilities that used to be found only
in SCADA systems, adding communications with Microsoft® Windows®-based HMIs, running on standard Ethernet
networks, and so on.
But now we need more from our automation systems. For the kinds of applications we want to do now and in the future,
we need a new approach that simplifies connections and communication—a new product that does much more than a
PLC or even a PAC. We need an automation product that shrinks or eliminates the middleware and lets us move data
from where it’s produced to where it needs to be in much fewer steps.
Fortunately that product has recently appeared on the market. It’s called EPIC—an Edge Programmable Industrial
Controller. An EPIC device eliminates middleware and shrinks the steps required to get the data we need, thus reducing
complexity, lessening security risks, and decreasing the time and expense required for installation and maintenance.
What exactly is EPIC? Let’s take a look at each part of the acronym and see what it means for the automation
applications we’re building, today and tomorrow.
Edge
All data acquisition starts at the edge, because that’s where data is produced. A manufacturing line or shipping
department in a factory, refrigerated rooms or barcoded containers in a warehouse, pumps and pipes and storage tanks
at remote sites: all are at the edge of the network and all have data that could be used to improve processes and profits.
If we can get that data directly from the source, then we know it’s accurate. So an EPIC device sits at the edge and
connects directly to sensors and actuators through its I/O, the inputs and outputs that gather sensor data and send
control commands. It also connects to existing PLCs or other devices to gather their data and issue commands, if
needed.
An EPIC device at the edge of the network actively works on the data as well, filtering out anomalies, labeling, storing
and transmitting only by exception to reduce unnecessary volume, and converting values from one protocol to another.
All this preprocessing makes operations, enterprise, and business cloud applications far more efficient.
Because it is the single source of truth for data, an EPIC device can also securely share this data with software and
equipment, including other control systems, building management systems, databases, cloud services, and others.
An edge device like this has:

• Integrated hardware and software that can perform control, monitoring, data acquisition, operator interface, edge
data processing, and analytical functions
• Quad-core processing power on a real-time, open-source operating system
• Two or more independent Ethernet network interfaces to segment a trusted network (for example, an internal
automation network) from an untrusted one (for example, a network with internet access)
• Gateway functions and a configurable internal firewall to control access to all network interfaces
• Authentication and encryption built into all communications; no default usernames or passwords

• User account creation and management based on required access to specific software on the system
• Support for modern security standards, for example PKI-standard certified connections to servers and clients using
SSL certificates
• Standard Ethernet network interfaces and standard modern computer ports like USB and HDMI for communications
• Multiple methods for communicating via standard automation and internet protocols
• Multiple software options for programming and data communications
• An integrated, user-configurable, web-based HMI that runs in a web browser, independent of device screen size,
manufacturer, or operating system
• An integrated high-resolution color touchscreen for local configuration of I/O and networks, troubleshooting, and
system visualization
• Agency approvals and compliance for hazardous areas
• Ratings for a wide range of operating and storage temperatures and relative humidity
Far more than just a controller, an EPIC’s open-source operating system and quad-core processing provide the
intelligence and speed of a computer. Its programming and communication options, PC-like ports, solid-state drives,
and file space offer options not available on a PLC or PAC. For example, you can store project files (like panel drawings,
P&IDs, installation notes) on an EPIC device, so they can be accessed in the field by authorized technicians.
For visualization, an EPIC device includes software for building a web-based, mobile-ready HMI. The HMI is not limited
to data and controls from one manufacturer only, but can let authorized users see and send data and manipulate
controls, if required, for multiple automation systems, software, and cloud services. Visible on the EPIC’s touchscreen,
this HMI is web-based and therefore also available to authorized users on computers, laptops, tablets, and smartphones.
Other options may also be available on an EPIC device. One example is open-source Node-RED for wiring together
devices, databases, cloud applications, and APIs (application program interfaces) with simple logic flows.
Programmable
An EPIC device is not a PLC, not a PAC, and not a PC, but like them it must be programmed for control. An EPIC device
gives you several programming options, some of which reflect traditional automation tools and others that come from PC
and internet backgrounds.
You can program control using familiar automation tools like flowcharting or any IEC 61131-3 compliant language,
including:
• Function Block Diagram (FBD)
• Structured Text (ST)
• Sequential Function Charts (SFC)
• Ladder Diagram (LD)
If you are more familiar with higher level languages, you can gain access to an EPIC’s open-source OS and choose to
build custom programs in languages you know, such as C/C++, Java, Python, or others.
An EPIC device does not limit your programming options like PLCs and PACs or force you to learn a new programming
language in order to use it. Instead, it lets you leverage what you already know, so you can build control, data exchange,
and HMI programs more quickly.

Industrial
As engineers, we often have to place controllers in severe environmental locations. One problem with PCs in industrial
automation is that an off-the-shelf PC cannot be trusted to stand up to harsh environments. Only a much more
expensive industrial PC will work.
In contrast, EPIC devices grew from real-world automation experience and were designed to withstand tough conditions.
Industrial-grade components and processors are designed for long life. UL hazardous locations approval and ATEX
compliance are standard. Operating temperature ranges are wide, for example, -20 to 70 °C. EPIC I/O is hot swappable.
Stainless-steel chassis come in different sizes to fit enclosures or machine designs and can be DIN-rail or panel
mounted.
Controller
At heart, an EPIC device is a real-time industrial controller designed to run control applications—a device that does
everything we have always expected from a PLC or PAC. Programmed with standard automation tools we already know,
like flowcharting, structured text, and even traditional ladder logic, an EPIC works just like a PLC or PAC in a control
system.
But an EPIC device is much more than just a controller. Its I/O modules offer multiple channels. Modules with isolated
channels are available. Analog and discrete I/O accept a variety of signals, with each channel usually software
configurable.
Because EPICs were designed by control engineers, they include features that simplify commissioning and
troubleshooting:
• A built-in touchscreen, usable with a finger, a stylus, or while wearing gloves

• A web-based system management application to configure I/O and networking on the touchscreen in the field, or
using a computer or mobile device
• I/O module specs and wiring diagrams viewable in the field, on the device
• Spring-clamp terminals and integrated, covered wireways that accommodate a variety of wire sizes
• LEDs on each I/O module that indicate module health and discrete channel status
An EPIC System
Taken as a whole, an EPIC system offers significant options for automation and IIoT projects that help future-proof your
investment.
Security—Unlike older automation controllers, an EPIC device includes tools to help you make your system as secure as
possible. Security starts when you are required to set up an administrator account before you can use the device—there
is no default username or password. A firewall is built in, communications are encrypted, user authentication is required,
and inbound connections are blocked by default. It’s still your responsibility to follow best practices and ensure the
security of your system, but an EPIC device gives you the tools to help.
Gateway functions—Because it has more than one independent network interface, an EPIC device can keep your
control system network segmented from untrusted networks. An untrusted network, for example, would be a company
computer network with an internet connection, which might be accessible by unauthorized users, including hackers.

Included HMI—Visualization to the system is built into an EPIC. The included HMI runs on the EPIC’s integrated
touchscreen or remotely on any brand computer or mobile device with a web browser. You determine the data that
appears in the HMI, which is not limited to the EPIC but can include any data and controls from equipment, software,
and online sources that are appropriate for your project and your users. You also control all user access rights to the
HMI, based on role.
Data communications—When data from an EPIC device needs to be used in other systems or software, many methods
are provided to do so, including ports on the controller and a variety of software and protocols to make data transfer
easier.
Scalability—An EPIC system is modular, so I/O can be changed or added to meet changing needs. More EPICs can
be added when your application grows. An EPIC device can act as a supervisory controller for other EPICs or industrial
controllers, or each EPIC can run independently and share needed data.
Control—For traditional real-time control, an EPIC system offers reliable I/O channels and multiple options for control
programming, including flowchart-based programming and familiar standard languages like ladder logic and function
block diagram.
Software upgrades—Like a smartphone or computer, an EPIC device can be updated to add new features just by
installing a software upgrade. You don’t have to replace hardware or change field wiring, and you don’t even have to
be where the EPIC is located, although you can be if you wish. Upgrades are installed through the EPIC’s web-based
management program, either from the EPIC’s onboard touchscreen or from a computer or mobile device.
Meeting the Challenge Glass Manufacturer: Solution
So how could an EPIC device help our

glass products manufacturer and our OEM
with their projects?
Glass manufacturer
The glass products manufacturer already
uses PLCs to control their existing
manufacturing lines. An EPIC device
can connect to these existing PLCs and
communicate their data.
The manufacturer won’t need to purchase

PLCs for the new lines they’re going
to add, however. EPIC processors can
be used instead, connecting directly to
sensors and actuators to provide control,
while communicating data wherever it is
needed.
Because the EPIC provides data in

standard engineering units, no conversion
software is required. Once configured with
plain-language names, I/O channels are available automatically as tags in all EPIC software, so no spreadsheets are
needed to keep track of points.

Incorporating production goals and sales from the company’s database is simpler with an EPIC, which includes software
such as Node-RED to acquire that data through pre-built nodes. Data from all sources—PLCs, sensors and devices
wired to the EPIC, and the company database—is easily made available to authorized users in the EPIC’s HMI software.
Using EPIC devices also makes future changes or expansion easier and more secure. In addition to providing
connections to PLCs and databases, an HMI, and real-time control, an EPIC can also move data among OPC servers,
business systems like MES and ERP, and cloud services and software.
Data from new sources can be added to the system without middleware. IIoT connections are encrypted and
authenticated. New data, controls, and authorized users can be easily added to the HMI, with changes pushed out to
users. You can see the possibilities in the included image.
OEM
The OEM’s engineers discovered the solution to both their security and cost concerns when they learned about EPIC
devices.
An EPIC in the oven replaces the PLC or industrial PC—or both—that used to be required. The EPIC is wired directly to
sensors and actuators in the oven and provides control, monitoring, data processing, communication, and visualization
in a single unit.
For control programming, the

OEM can use flowcharting, IEC
61131-3 languages, or Secure Shell
access (SSH) for a custom program
running on the Linux OS.
For an improved HMI, the OEM has

choices:
• On smaller ovens, the EPIC’s
built-in touchscreen can
provide local visualization.
• On larger ovens, an industrial
monitor can be added, plugged
into the EPIC’s HDMI port.
• For all ovens, the OEM can
build a secure web-based
HMI for use on computers and
mobile devices. This HMI can
be used by customers and also
by the OEM.
Because the EPIC’s system

management software is web-based, the OEM can apply software updates and manage the oven from their location,
rather than having to go to the customer’s site.
Secure data from customer sites
Perhaps the greatest advantage of an EPIC device for the OEM, however, is the ability to get the data they want from
their ovens at customer sites, without causing security issues for the customer.

In addition to the usual request/response method for data communication, an EPIC offers another method: publish/
subscribe.
Publish/subscribe, or pub/sub, works by setting up a central broker, either on premises or in the cloud. The broker
handles all data communications. Each data source sends data to the broker only when it changes (report by exception).
Equipment and software that need data subscribe to only the data they need, and they receive it from the broker only
when it changes.
Most important from a security standpoint, all communications are device-originating, outbound-only connections from
the EPIC to the broker over secure, encrypted connections. (Secure, device-originating, outbound connections are
normally permitted by most IT departments.) Once initiated, data can flow in both directions. Firewalls allow outbound
communications, so there’s no need to open unsecure ports in firewalls. Security is maintained and IT involvement is
reduced. (See more information on pub/sub.)
Because it greatly reduces network traffic and maintains security, a pub/sub communication method is ideal for remote
locations. With an EPIC in their ovens, the OEM can set up a pub/sub broker at their facility or in the cloud and transfer
data from ovens at customer sites, via outbound communications, anywhere they need to use it. For example:
• In the HMI for monitoring and controlling

• In a database for analysis to improve oven design
• In software for tracking individual customer service
• In online artificial intelligence and machine learning services for analyzing wear and determining preventive
maintenance schedules, or predicting when failures might occur to reduce or eliminate downtime.
EPICs available now
The first EPIC device on the industrial automation market comes from Opto 22, a controls manufacturer with more than
40 years of experience, who designed their groov EPIC® system to meet the present and future needs of automation
engineers. Their EPIC device was released in May 2018, and quarterly software updates since then continue to add
significant features.
Manufactured in the U.S.A., Opto 22’s groov EPIC has the characteristics of an edge programmable industrial controller
discussed in this white paper. A short list of its hardware features includes:
• Open-source Linux® OS, industrial quad-core ARM® processor, solid-state drive, 6 GB user file space
• Two independent Gigabit Ethernet network interfaces, plus HDMI and USB ports for an external or touchscreen
monitor, serial networking, WiFi adapter, or other use
• Integrated high-resolution color touchscreen
for system configuration, management, and
HM
• Guaranteed-for-life I/O modules (discrete,
analog, serial) with 8-24 channels per module
and a wide variety of signal types. I/O is hot-
swappable and self-discovering. Channel-to-
channel isolation is available
• Stainless-steel 4-, 8-, or 16-module chassis,
DIN-rail or panel mounted, with integrated
power supply (AC, DC, or pass-through)

• Easy-access spring-clamp terminals with a covered wireway; 28–14 AWG wire
• Wide -20 to 70 °C operating temperature range
• UL Hazardous Locations approval and ATEX compliance
This EPIC device also offers an array of software for control programming, HMI development and runtime,
and data sharing (all software is included in the EPIC processor’s purchase price except as noted):
• Web-based system management software for tool-less configuration, commissioning, and debugging, onboard and
from anywhere on the network
• Flowchart-based control programming with optional scripting
• Support for all IEC 61131-3 compliant control languages, including Function Block Diagram (FBD), Structured Text
(ST), Sequential Function Charts (SFC), and Ladder Diagram (LD) through the CODESYS® Development System
• HMI software for building and securely viewing operator interfaces from the EPIC’s touchscreen and from any mobile
device or PC with a web browser
• Ignition Edge® (a product of Inductive Automation®) to connect to any OPC UA server, with OPC-UA drivers to
Allen-Bradley® and Siemens® PLC systems and Modbus®/TCP devices (extra cost)
• Publish/subscribe method for efficient data communications (MQTT transport protocol with Sparkplug payload; extra
cost)
• Open-source Node-RED for wiring together APIs, cloud applications, and databases using pre-built nodes
• RESTful API to the EPIC processor and HMI software
• Optional secure shell access (SSH) for developing and running a custom application using C/C++, Python, or other
languages (extra cost)
Looking ahead
As we’ve seen, EPIC devices offer a new kind of industrial controller—an edge programmable industrial controller
that not only gives automation engineers real-time control for all kinds of traditional automation applications, but also
positions them to be able to provide the IIoT and data-based tasks companies want to do now.
EPIC devices free you to focus on what you want to do: connect legacy systems and smart systems, get data, transform
it into actionable information, visualize it when and where you want, and perform real-time control.
Because EPIC systems are so scalable, they can be applied to smaller applications and then expanded with virtually no
limitation. You can see how EPIC can work for you before committing significant resources.
An EPIC device offers a simple, secure, maintainable, and cost-effective solution for data communication. If solving your
latest challenge involves complex steps, expensive middleware, or security issues, take a look at an EPIC device. You
may very well find it can shrink those steps, reduce your costs, and help provide the security you need.
About the author:
Benson Hougland
VP Marketing and Product Strategy
With 30 years’ experience in information technology and industrial automation, Benson
Hougland drives strategy for Opto 22 products connecting the real world of OT to the systems
and networks of IT. Benson speaks at trade shows and conferences, including IBM Think,
ARC Forum, and ISA. His 2014 TEDx Talk introduces non-technical people to the IoT.

Smart Manufacturing: Keep Your Competitive Edge
By: John Clemons, MAVERICK Technologies
During the past decade, manufacturers have seen a flood of operational intelligence or “Big Data.” The result of this
influx? Manufacturers can now reap the benefits of a plethora of smart manufacturing tools, devices and new technology
platforms, such as the Industrial Internet of Thing (IIoT) and Industry 4.0.
Manufacturers who ride the smart manufacturing wave will have a competitive edge while those who take a wait-and-see
approach will get left behind. Why? Today’s consumers use smart technology and are more tech-savvy than ever. They
expect on-demand access to new and different, high-quality products. They want more customizable bells and whistles
at lower costs along with quick response times and service. In this fast-paced market, if you don’t serve your customers,
your competitors will.
So why wait? Smart manufacturing provides several ways companies can become more data-driven, agile, innovative,
profitable and sustainable.
A Flat World
Smart manufacturing supports flat organizations. It supports eliminating layers of middle management to make the
organization agile and responsive. Smart manufacturing is about flattening out the organization so the company can
respond very quickly to rapidly changing market demands and ever-increasing global competition.
In the old days, computer architectures in manufacturing were just as hierarchical as the company organizations. People
even called the architecture models names like the “computer-integrated manufacturing (CIM) Pyramid” and called each
system in the pyramid a “level” with all the levels numbered from bottom to top. With these hierarchies, all the data had
to flow up and down to get anywhere. That did nothing but create silos of information that were of little value to anyone
but the few people who were part of a given silo.

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